Process for breaking petroleum emulsions



fiatented Feb. 20, 1951 'PROCESS FOR BREAKING PETROLEUM EMULSIONS Melvin De Groote, University City, and Bernhard Keiser, Webster Groves, Mo., assignors to Petrolite Corporation, Ltd., Wilmington, Del., a corporation of Delaware No Drawing. Application December 13, 1948, Serial No. 65,080

20 Claims.

This invention relates to processes or procedures particularly adapted for preventing, breaking, or resolving emulsions of the water-in-oil type, and particularly petroleum emulsions. This invention is a continuation-in-part of our copending application Serial No. 726,205, filed February 3, 1947 (now abandoned). See also our co-pending applications Serial No. 8731, filed I'February 16, 1948 (now abandoned), and also Serial No. 42,134, filed August 2, 1948 (now abandoned). Attention is also directed to our coiiriding application Serial No. 64,469, filed 'December 10, 1948. Complementary to the above aspect of the invention is our companion invention concerned with thenew chemical products or compounds used as the demulsifying agents in said aforementioned processes or procedures, as well as the application of such chemical compounds, prod-- nets, and the like, in various other arts and inidustries, along with the method for manufacturingsaid new chemical products or compounds which are of outstanding value in demulsification. See our co-pending application Serial No.' 65,081, filed December 13,1948;

Our invention provides an economical and rapid process for resolving petroleum emulsions of the water-in-oil type, that are commonly reetc" and Whichcomprise fine droplets of naturally-occurring waters or brines dispersed in a :more or less permanent state throughout the oil which constitutes the continuous phase of the emulsion.

. Italso provides an economical and rapid process for separating emulsions which have been prepared under controlled conditions from mineral ioil, such as crude oil and relatively soft waters or: weak brines. Controlled emulsification and subsequent demulsification, under the conditions just mentioned, are of significant value in removing impurities, particularly inorganic salts, from pipeline oil.

Demulsification, as contemplated in the present application, includes the preventive step of ,commingling the demulsifier with the aqueous component which would or might subsequently become either phase of the emulsion in the ab,

sence of such precautionary measure. Similarly, such demulsifier may be mixed with the hydrocarbon component.

Briefiy stated, the present process is concerned with the breaking or resolving of petroleum emulsions by means of certain esters which are, in turn, derivatives of specific synthetic products. These products are, in turn, the oxyalkylated derivatives of certain resins hereinafter specified.

Thus, the present process is concerned with breaking petroleum emulsions of the Water-inoil type, characterized by subjecting the emulsion to the action of a hydrophile ester of an alpha-halogen monocarboxylic acid having not over 6 carbon atoms and hydrophile hydroxylated synthetic products; said hydrophile synthetic products being oxyalkylation products of (A) An alpha-beta alkylene oxide having not more than 4 carbon atoms and selected from the class consisting of ethylene oxide, propylene oxide, butylene oxide, glycide, and methylglycide; and

(B) An oxyalkylation-susceptible, fusible, organic solvent-soluble, water-insoluble, phenol- -aldehyde resin; said resin being derived by reaction between a difunctional monohydric phenol and an aldehyde having not over 8 carbon atoms and reactive towards said phenol; said resin being formed in the substantial absence of trifunctional phenols; said phenol being of the formula:

in which R is a hydrocarbon radical having at least 4 and not more than 12 carbon atoms and substituted in the 2,4,6 position; said oxyalkylated resin being characterized by the introduction into the resin molecule of a plurality of divalent radicals having the formula (R10) n, in which R1 is a member selected from the class consisting of ethylene radicals, propylene radicals, butylene radicals, hydroxypropylene radicals, and hydroxybutylene radicals, and n is a numeral varying from 1 towith the proviso that at least 2 moles of alkylene oxide be introduced for each phenolic nucleus; and with the final proviso that the hydrophile properties of the ester as well as the oxyalkylated resin in an equal weight of xylene are sufiicient to produce an emulsion when said Xylene solution is shaken vigorously with one to three volumes of water.

For purpose of convenience, what is said hereinafter will be divided into four parts. Part 1 will be concerned with the production of the resin from a difunctional phenol and an aldehyde; Part 2 will be concerned with the oxyalkylation of the resin so as to convert itinto a hydrophile hydroxylated derivative; Part 3 .will be concerned with the conversion of the immediately aforementioned derivative intoa total or partial ester by reaction with chloroacetic acid, or the like; and Part 4 will be concerned with the use of such esters as demulsifiers, as hereinafter described.

PART 1 ;As to the preparation'oftheiphenol-aldehyde resins reference is madecto ourco-pendingapplications, Serial Nos. 8,730 and 8,731, .both filed February 16, 1948 (both nowabandoned). In such co-pending applications we described. a fusible, organic solvent-soluble, water-insoluble resin polymer of the formula "as reactants, then the aldehydes, and finallythe phenols, for the reason that the .la-tterzrequirea more elaborate description.

The alkylene oxides which may be used are the alpha-beta oxides having not more than 4 carbon atoms, to wit, ethylene oxide, alpha-beta propylene oxide, alpha-beta butylene oxide, glycide, and methylglycide.

Any aldehyde capable. of forming a methylol or a substituted methylol group and having not more than 8 carbon atoms is satisfactory, so long as it does not possess some other functional group or structure which will conflict with the resinification reaction or with the subsequent Qxyalkylation of the resin, but the use of formaldehyde, in its cheapest form of an aqueoustsolution, for the production of the resinsv is .particularly advantageous. Solid polymers of formaldehyde are more expensive and higheraldehydes are both less reactive, and are more expensive. Furthermore, .the higher aldehydes may undergo other reactions which are not *de: sirable, thus introducingdifilculties intothere 4 sinification step. Thus acetaldehyde, for ex-' ample, may undergo an aldol condensation, and it and most of the higher aldehydes enter into self-resinification when treated with strong acids or alkalies. On the other hand, higher aldehydes frequently beneficially affect the solubility and fusibility of a resin. This is illustrated, for example, by the difierent characteristics of the resin prepared from para-tertiary amylphenol and formaldehyde on one hand, and

.a comparable product prepared from the same phenolic reactant and heptaldehyde on the other hand. The former, as shown in certain subsequent examples, is a hard, brittle, solid, whereas the latter. isLsoft-and tacky, and obviously easier to. handle in the subsequent oxyalkylation procedure.

Cyclic aldehydesmay be employed, particularly benzaldehyde. The employment of furfural requirescareful control for the reason that in addition to its aldehydic function, furfural can form vinylcondensations by virtue of its unsaturated structure. The production of resins from furfural for .use in preparing reactants for the present process is most conveniently conducted with weak alkaline catalysts and often with alkali metal carbonates. Usefulaldehydes, in addition to formaldehyde, are acetaldehyde, propionic'aldehyde, butyraldehyde, 2-ethylhexanal, ethylbutyraldehyde, heptaldehyde, and benzaldehyde, iurfural .and glyoxal. It would appear that the use of glyoxal should be avoided dueto the fact that it is tetrafunctlonal. However, our experience has been that, in resin manufacturefind particularly as. described here in,.apparent1y only one of. the aldehydic .functlonsenters intoithe resinification reaction. [The inabilityof the other aldehydic function to enter intothe reactionjjs presumably dueto steric hindrance. Needless; to say, one can use a mixtureof. two or more aldehydesalthoughusually thishas. no advantage.

Resins of the kindwhichareusedas intermediates in this invention. are obtained withthe use of acid catalysts or alkaline catalysts, ,or Without the use of any catalyst at all. Among the useful alkaline catalysts .are ammonia, amines, and quaternary ammonium bases. ItiS generally accepted that whenammonia and amines are employed as catalysts they enter into the condensation reaction and, in fact, may operate by initial combination with the aldehydic reactant. The compound hexamethylenetetramine illustrates such a-combination. 'In'light of these various reactions it becomes 'difiicult to present any formula which would depict the structure -of the various resins prior to oxyalkylation. More will be said subsequently as to'the difference between the use of'. an alkalinecatalyst and .an. acid catalyst; even in the use ofan alkaline catalyst there is considerable evidence to indicatelthat the products are. not identical where difierent basic materials are employed. The basic=imaterials employed include not only those previously enumerated but also the hydroxides of'the. alkali metals, hydroxides of the alkaline earth metals, salts of strong bases and-weak acids such as so.- dium acetate, etc.

Suitable phenolic reactants include the follow. ing: Para-tertiarybutylphenol; para-secondarybutylphenol; para-tertiary-amylphenol; parasecondary-amylphenol; para-tertiary-hex-ylphenol; para-isooctylphenol; ortho-phenylphenol; para-phenylphenol; ortho-ebenzylphenol; parabenzylphenol; and para-cyclohexylphenol, and

the corresponding ortho-para substituted metacresols and 3,5-xy1enols. Similarly, one may use paraor ortho-nonylphenol or a mixture, paraor ortho-decylphenol or a mixture, menthylphe- 1101, or paraor ortho-dodecylphenol.

For convenience, the phenol has previously been referred to as monocyclic in order to differentiate from fused nucleus polycyclic phenols, such as substituted naphthols. Specifically, m-onocyclic is limited to the nucleus in which the hydroxyl radical is attached. Broadly speaking, where a substituent is cyclic, particularly aryl, obviously in the usual sense such phenol is actually polycyclic although the phenolic hydroxyl is not attached to a fused polycyclic nucleus. Stated another way, phenols in which the hydroxyl group is directly attached to a condensed or fused polycyclic structure, are excluded. This matter, however, is clarified by the following consideration. The phenols herein contemplated for reaction may be indicated by the following formula:

in which R is selected from the class consisting of hydrogen atoms and hydrocarbon radicals having at least 4 carbon atoms and not more than 12 carbon atoms, with the proviso that one occurrence of R is the hydrocarbon substituent and the other two occurrences are hydrogen atoms, and with the further provision that one or both or the 3 and positions may be methyl substi tuted.

The above formula possibly can be restated more conveniently in the following manner, to wit, that the-phenol employed is of the following formula, with the proviso that R is a hydrocarbon substituent located in the 2,4,6 position, again with the provision as to 3 or 3,5 methyl substitution. This is conventional nomenclature, numbering the various-positions in the usual clockwise manner, beginningwith the hydroxyl position as one:

The manufacture of thermoplastic phenolaldehyde resins, particularly from formaldehyde and a difunctional phenol, i. e., a phenol in which oneof the three reactive positions (2,4,6) has been substituted by a hydrocarbon group, and particularly by one having at least 4 carbon atoms and not more than 12 carbon atoms, is well known. As has been previously pointed out, there is no objection to a methyl radical provided it is present in the 3 or 5 position.

Thermoplastic or fusible phenol-aldehyde resins are usually manufactured for the varnish trade and oil solubility is of prime importance. For this-reason, the common reactants employed are butylated phenols, amylated phenols, phnylphenols, etc. The methods employed in manufacturing such resins are similar to those employed in the manufacture of ordinary phenol-formaldehyde resins, in that either an acid or alkaline catalyst is usually employed. The procedure usually differs from that employed in the manufacture of ordinary phenol-aldehyde resins in that phenol, being Water-soluble, reacts readily with an aqueous aldehyde solution without further difficulty, while when a water-insoluble phenol is employed some modification is usually adopted to increase the interfacial surface and thus cause reaction to take place. A common solvent is sometimes employed. Another procedure employs rather severe agitation to create a large interfacial area. Once the reaction starts to a moderate degree, it is possible that both reactants are somewhat soluble in the partially reacted mass and assist in hastening the reaction. We have found it desirable to employ a small proportion of an organic sulfo-acid as a catalyst, either alone or along with a mineral acid like sulfuric or hydrochloric acid. For example, alkylated aromatic sulfonic acids are effectively employed. Since commercial forms of such acids are commonly their alkali salts, it is sometimes convenient to use a small quantity of such alkali salt plus a small quantity of strong mineral acid, as shown in the examples below. If desired, such organic sulfo-acids may be prepared in situ in the phenol employed, by reacting concentrated sulfuric acid with a small proportion of the phenol. In such cases where xylene is used as a solvent and concentrated sulfuric acid is employed, some sulfonation of the xylene probably occurs to produce the sulfo-acid. Addition of a solvent such as xylene is advantageous as hereinafter de scribed in detail. Another variation of procedure is to employ such organic sulfo-acids, in the form of their salts, in connection with an alkalicatalyzed resinification procedure. Detailed examples are included subsequently.

Another advantage in the manufacture of the thermoplastic or fusible type of resin by the acid catalytic procedure is that, since a difunctional phenol is employed, an excess of an aldehyde, for instance formaldehyde, may be employed without too marked a change in conditions of reaction and ultimate product. There is usually little, if any, advantage, however, in using an excess over and above the stoichiometric proportions for the reason that such excess may be lost and wasted. For all practical purposes the molar ratio of formaldehyde to phenol may be limited to 0.9 to 1.2, with 1.05 as the preferred ratio, or sufficient, at least theoretically, to convert the remaining reactive hydrogen atom of each terminal phenolic nucleus. Sometimes when higher aldehydes are used an excess of aldehydio reactant can be distilled off and thus recovered from the reaction mass. This same procedure may be used with formaldehyde and excess reactant recovered.

When an alkaline catalyst is used the amount of aldehyde, particularly formaldehyde, may be increased over the simple stoichiometric ratio of one-to-one or thereabouts. With the use of alkaline catalyst it has been recognized that considerably increased amounts of formaldehyde may be used, as much as two moles of formaldehyde, for example, per mole of phenol, or even more, with the result that only a small part of such aldehyde remains uncombined or is subsequently liberated during resinification. Structines-which have i been, advanced; to explain such increased use, of ,aldehydes arethe following:

Such'structures may lead tothe production-of cyclic polymers instead of linear polymers- For this reason, it has heenpreviously pointed out that,a1though linear polymers have by farthe most importantsignificance, the present invention does not exclude resins of such cyclic structures.

Sometimes conventional resinification procedure is employed using eitheracid or alkaline catalysts to produce low-stage resins. Such resins maybe employed as such, or may be altered or converted into high-stage resins, or in any event. into resins of higher molecular weight, by heating along with the employment of vacuum so as to split off water or formaldehyde, orboth. Generally speaking,-temperatures employed, particularly with vacuum, maybe in the neighborhood 1 of 175 to 250 'C., or thereabouts.

It may be well to point out, however, that the amount of formaldehyde used may and does usually affect the length of the resin chain. In creasing the amount of the aldehyde, such as formaldehyde, usually increases the size or molecular Weight of the polymer.

In the hereto appended claims there is specified, among other things,.the resin polymer containing at least3 phenolic nuclei. Such minimum molecular size is most conveniently determined as arule by cryoscopic method using benzene, or some other suitable solvent, for instance, one of those mentioned elsewhere herein as a solvent for such resins. .As a matterv of .fact,1using .the procedures herein described. or any conventional resinification procedure will yield products usually having definitely in excess of 3 nuclei. In. other words, a resinhaving an average of.4, 5 or 5 nuclei per unit isapt to beforined as a minimum in resinification, except undercertain special conditions where dimerization may occur.

,.However,if resins are prepared at substantially higher temperatures, substituting cymene, tetralin,,etc., or some other suitable solvent which boils or refiuxes at a higher temperature, instead of xylene, in subsequent examples, and if one doubles or triples the amount of catalyst, doubles or triples the time of refluxin uses a marked excess of formaldehyde or other aldehyde, then the average size of the resin is apt to be distinctly over the above values, for example, it may average 7 to 15 units. Sometimes the expression lowstage resin or low-stage intermediate is employed to mean a stage having 6 or 7 units or evenless. In the appended claims'we have used low-stage to mean 3 to 7 units based on average molecular weight.

4 The molecular weight determinations, of course, require thatthe productbe completely sesame soluble r inz-the .;particular solvent selected as, for instance benzene. The .molecular We ght-idetermination-of such solution may involve; either the=-freezing point as in the. cryoscopic,.method, or, less conveniently perhaps, the boiling point inan ebullioscopicmethod. The: advantagevof the ebullioscopic methodv is that,;in.,c0mparison with the cryoscopic method, it: is more apt;,to insure. completezsolubility. One ,such common method tQ-emplOy is that of Menzies and- Wright .(see J, Am.-Chem. $00.43, 2309 and,2314 (1921-) Any' suitable method for determining molecular Weights will serve, although almost any. procedure adopted has inherent limitations. A good method for-determining the molecular weights of resins, especially, solvent-soluble resins, is, the cryoscopic procedure. of Krumbhaar .1 which; employs @di-- phenylamineuas a; solvent .(see Coating -,and,l,nk Resins," page 157, Reinhold Publishing Co. 1947) Subsequentexampleswill illustrate the useiof an acidcatalyst, an alkalinecatalyst,,andmo catalyst. As far as resin manufacture peruse is concerned, we prefer to use an acid catalyst, and particularly a mixture of an organic sulfoacid and a mineral acid, along with a suitable solvent, such as xylene, ashereinafter illustrated in detail. However, we have obtained products from resins obtained by use of an alkaline catalyst which were just as satisfactory as those obtained employing acid catalysts. Sometimes a combination of both types of catalysts is used in different stages of resinification. Resins so obtained are alsoperfectly, satisfactory.

in numerous instances the higher molecular weight resins, i. e., thosereferred, to .as. high-stage resins,v are convenientlyobtained by subjecting lowermolecular weight resinstovacuum distil= lation and heating. Although such, procedure sometimes removes only a .modest ,amountor evenperhaps no. 10W polymer, yet it is almost cer-' tain to produce further polymerization. For instance, acid catalyzed resins obtained in the usual manner and having a molecular weight indicating the presence of approximately 4 phenolic unitsor thereabouts may be subjected to such treatment, with the result that one obtains-a resin having approximately double this molecular weight. The usual procedure is to usea secondary step, heating the resin in the. presence ,or absence of an inert gas, including steam, or by use of vacuum.

We have found that under the usual conditions of resinification employing phenols of the kind here described, there is little or no tendency to form binuclear compounds, 1. e., dimers, resulting from the combination, for example, of 2 moles of a phenol and one mole of formaldehyde, particularly where the substituent has 4 or 5 carbon atoms. Where the number of carbon atoms in a substituent approximates the upper limit specified herein, there may be some tendency to dimerization. The usual procedure to obtain a dimer involves an enormously large excess-of the phenol, for instance, 8 to 10 moles per mole of aldehyde. Substituted dihydroxydiphenylmethanes obtained from substituted phenols are not resins as that term is used herein.

Although any conventional procedure .ordi narily employed may be used inthe manufacture of the herein contemplated resins or, for that matter, such resins may be purchased. in the open market, we have found it particularly-desirable to use the procedures described elsewhere herein, andempl yinaa combination of an organic sulfoacid and a mineral acid as a catalyst, and' xylene as a solvent. By way of illustration, certain-sub-E sequent examples are includechbut it is, to be understood the herein described inventionis not, concerned with the resins per se or with any particular method of manufacture but is concerned with the use of reactants obtained by the subse-- quent oxyalkylation thereof. The phenol-aldehyde resins may be prepared in any suitable.-

manner.

Oxyalkylation, part cularly oxv thviation which is the preferred reaction, depends on contact be-- tween a non-gaseous phase and a gaseous phase. It can, for example, be carried out by melting the thermoplastic resin and subjecting it to treatment with ethylene oxide or the like, or by treating a suitable solution or suspension. Since the melting points of the resins are often higher than desired in the initial stage of oxyethylation, we have found it advantageous to use a solution or suspension of thermop astic resin in an inert solvent such as xylene. Under such circumstances, the resin obtained in the usual manner is dissolved by heating in xylene under a reflux condenser or in any other suitable manner. Since xylene or an equivalent inert solvent is present or may be present during oxyalkylation, it is obvious there is no objection to having a solvent present during the resinifying stage if, in addition to being inert towards the resin, it is also inert towards the reactants and also inert towards water. Numerous solvents, particularly of aromatic or cyclic nature, are suitably adapted for such use. Examples of such solvents are xylene, cymene, ethyl benzene, propyl benzene, mesitylene, decalin (decahydronapht alene) tetralin (tetrahydronaphthalene) ethylene glycol diethylether, diethylene glycol diethylether, and tetraethylene glycol dimethylether, .ormixtures of one or more. Solvents such as dichloroethylether, or dichloropropylether may be employed either alone or in mixture but have the objection that the chlorine atom in the compound may slowly combine with the alkaline catalyst employed in oxyethylation. Suitable solvents may be selected from this group for molecular weight determinations.

The use of such solvents is a convenient expedient in the manufacture of the thermoplastic resins, particularly since the solvent gives a more liquid reaction mass and thus prevents overheating, and also because the solvent can be employed. in connection with a reflux condenser and a Water. trap to assist in the removal of water of reaction and also water present as part'of the formaldehyde reactant when an aqueous solution of formaldehyde is used. Such aqueous solution, of course, with the ordinary product of commerce. containing about 37 to 40% formaldehyde, is

the preferred reactant. When such solvent is used it is advantageously added at the beginning of the resinification procedure or before the reaction has proceeded very far.

The solvent can be removed afterwards by dis- 6 i March 7, 1950. If the resin so obtained is solventtillation with or without the use of vacuum, and a final higher temperature can beemployedto complete reaction if desired. In many instances it is most desirable to permit part of the solvent,

particularly when it is inexpensive, e. g., xylene, 7p

to remain behind in a predetermined amount so as to have a resin which can be handled more conveniently in the oxyalkylation stage. If a.v more expensive solvent, such as decalin, is em-.

, grade.

be added after the removal of decalin, if desired-, In preparing-resins fromdifunctional phenolss it is common to employ reactants of technical The substituted phenols herein contemefi plated are usually derived from hydroxybenzene;- As a rule, such substituted phenols are compara-= tively free from unsubstituted phenol. We have generally found that the amount present is con-. siderably less than 1% and not infrequently in the neighborhood of 6 of 1%, or even less. The: amount of the usual trifunctional phenol, suchas hydroxybenzene or metacresol, which can be 1101-; erated is determined by the fact that actualcross-linking, if it takes place even infrequentlm, must not be sufiicient to cause insolubility at the completion of the resinification stage or the lack of hydrophile properties at the completion of the oxyalkylation stage.

The excluson of such trifunctional phenols hydroxybenzene or metacresol is not based on:

the fact that the mere random or occasional in clusion of an unsubstituted phenyl nucleus in the resin molecule or in one of several molecules, for example, markedly alters the characteristics of the oxyalkylated derivative. The presence of a phenyl radical having a reactive hydrogen atom available or having a hydroxymethylol or a sub-- stituted hydroxymethylol group present is a po-- tential source of cross-linking either during. resinification or oxyalkylation. Cross-linking leads either to insoluble resins or to non-hvdro-r. philic products resulting from the oxyalkylation procedure. With this rationale understood, it is obvious that trifunctional phenols are tolerableonly in a minor proportion and should not be present to the extent that insolubility is produced inthe resins, or that the product resulting from oxyalkylation is gelatinous, rubbery, or at leastnot hydrophile. As to the'rationale of resinificae; tion, note particularly what is said hereafter-in. differentiating between resoles, Novolaks; and-- resins obtained solely from difunctional phenols.

Previous reference has been made to the fact. that fusible organic solvent-soluble resins are usually linear but may be cyclic. Such more, complicated structure may be formed, particu-- larly if a resin prepared in the usual manner is. converted into a higher stage resin by heat treatment in vacuum as previously mentioned. This.

again is a reason for avoiding any opportunity for.

tion procedure, or in the oxyalkylation procedure;

cross-linking due to the presence of any appreciable amount of trifunctional phenol. In other words. the presence of such reactant may cause cross-linking in a conventional resinificaor in the heat and vacuum treatment if it is em ployed as part of resin manufacture.

a Our routine procedure in examining a phenol for suitability for reparing intermediates to be used in practicing the invention is to prepare a; resin employing formaldehyde in excess (12 moles of formaldehyde per mole of phenol) and, using an acid catalyst in the manner described. in Example 1a of-our Patent 2,499,370, granted soluble in any one of the aromatic or other 501:1. vents previously referred to, it is then subjected to oxyethylation. During oxyethylation a temperature is employed of approximately to .C. with addition of at least 2 and advantage ously up to 5 moles of ethylene oxide per phenolic hydroxyl. The oxyethylation is advantageously. conducted so as to require from a few minutes up p y d. Xyl ne or. other inexpensive solvent may 75 to Etc ,10 hours. If the product so obtained is estates:-

perfectlysatisfactoryfrom thezstandpoint or-trifunetional phenol content?" The solvent may be removedpriorto the dispersibilit or emulsifi :a'hili'ty-test; When a product becomes rubbery during" oxyalky-lation *due' to' the presence of "a small amountof 'trireactive' phenol, as previously mentioned; or'ior some other reason; it may-"bec'ome extremely insoluble, andno'longerqu'aufies its-"being hydrophi'leasherein specified. Increas insure size of the aldehydic'nucleus, forinstanoe using heptaldehyde instead of formaldehyde, in creases tolerance 'for'trifunctional' phenol;

" V The presence of a trifunctional or "tetrafunw tit-mem-e eaepasaeeagerness ableyonha emulsifying'properti'es, the phenol is tionarphenm-( sucrr asresorcinol or bisphenol A). isiapt' toproduce'detectabie cross-nnkirieand-in- 7 solubilization but will not necessarily doso, es

peciany ifthe' roportion'is small; Resinification,

ifivol vingdifunctionalphenols onl may' alsopro duceinsolubiliz'ation, although this seems to be an-"anomalyor a contradiction of what is s'ome-- times-said in regard to resinification reactions involving-'difunctionalphenolsonly. This is presumably due to cross-linking. This'appears' to hei contra'dictoi'yto what one might expect in lig'ht' oflthe theory of'functitinality in resinifica'-- not. It is" truethat "under ordinary? on;

cumstanc'ea'or rath'i under the circumstances-of conventionerresin manufacture, the procedures employing difunctional phenols are very'apt'to, and'almost invariablydo, yield solvent-soluble, fusible resins However; whenconventional pro-'- cedui'es' areemployedin connectionwith resins for'varnishmanufacture or the like; thereis"in'- voived'the matter of color; solubility in oil; etc.

resins "of thesametyp'eare' manufactured IoriT-the-herein-contemplatedpurpose; i. e.; as a raw materiai to ts-subjectedto oxyalkyi'a'tion, such riteriaof selection areno longer pertinent. Statedanother Way, one mayuseinore drastic conditions of resinific'ationthan those ordinarily employed to produce'resins for'the presentpurposes? such' 'more 'drasticconditions of fresinifi cat-ion may'include'increased'amounts of catalyst, higher temperatures, longer'tirne of reaction, sub-* se-quent-reaction involving heat alone or in com-=- binationwith vacuumyetcp Therefore; one is not only" concerned" withthe' resinification reactions which yieidtne bulk of ordinary resins from di' functional phenols but alsoand particularly'with' the minor reactions of ordinar'y" resin 'manufae tuiewhich'are of importance inthe present inventionfor the reason'that they occur under more" drastic conditions of resinific'ation which'i'nay be employed advantageously at-times; and they lead to cross-linking;

In this connection it maybe well to "point out that part fof'these reactions are now understood or "explainable' to 'a greater or" iesseruegree" in IYghtbfafmOSt recent investigation: Referenceis 'made [to the "researches of "Zinke and his "coworkersiI-Iultzsch and his associates, and to von Eul'en and his 'co-work'ers, and others. As to a bibliography" of such investigations, see 'Carswell, "pn'enoplastsw chapter "2. These investigators limited mucl'r'of 'their'work" to reactions involv in'g 'phen'ols' having two-"or less reactive hydrogen atoms"? Much of what a i'ipears in thesemost re: cent and mostup-to-date investigations is pertinent to'th'e present invention insofar that much, of; is referring to resinifi'cation invoivin un funct onalhenols;

:Fditthmdment, it may lee-simpler to consider a "mhst1itypica1 type offusible resin and" forget" efitime' t a such r'esin,:at leastunder'cer tam :eircumstances,= is susceptible to further com-3 plications:'- Subsequently in the text it will be pnenoiresinma be heated indefinitely Withoutpassin'ginto an infusi-bl'e stage, and in this re spect is similartoa N'ovolaki Unlike theNovol'ak. type: the'ad'dit-ion of-a further reactant, for instance,"morealdehyd'e, does not ordinarily alter fusibilityof the difu'nctional phenol-aldehyde type resinj'but such addition to a 'Novolak causes cross=linking by*virtue of the available third functional position.

What has'been sa'id immediately preceding is subject-to modification inthis respect: It is Well known, for example, that difun'ctional phenols, foi instanee-;= para'tertiaryamylphenol, and an aldehyde, particularly forma1dehyde', rnay yield heatharden'ab1e resins, at least under certain conditions; esior example the use of two moles of-formaldehydeto one of phenol, along With'an alkalinelcatalyst. 1 This peculiar hardening of ou'ring or-cross linkingof resins obtained from difunctional phe'nols hasbeen recognized by vari ous authigi'riti"es";

The inter'mediate herein used must be hydrophi-l'e. or".suhPsurface-activ'e' or surface-active as vo'IVi'nE'fO'r'maIdehyde, for example, and a difunctional" phenol would not be expected to form cross.- links. However, cross-linking sometimes occurs ar'idlit inay'reachth'e objectionable stage. Ho'w ever, "provided"that the "preparation of resins simplftakes-into cognizance the present knowledge-or the *subject, and employing preliminary, exploratory routine examinations. as herein indicated, there is 'not'th'e slightest dificulty' in preparing'avery'darge number'of resins of various at typesiand-fromvarious reactants, and by means off-different catalysts by different procedures, all of which'r'are" eminently suitable for .the herein descr'i ed purpose.

Now-returning to the thought that cross-linkng-canstake. place, even when difunctional phenois "areused' exclusively, attention is directed to thefollow'i ngr' Somewhere during the course of resin manufacture there'm'aybe a potential cross:- linking' combination formed but actual cross v linking may not take place'until .thesubsequent stage-is reached, i. e., heat and vacuum stage, or--oxyeiky1ation stage." This situation.- may be relatedor'explained in terms of a theory of flaws, oi"Lockeistellen;'which is employed in explaining fiaw-forming groups due to the fact that a CI-lzOI-I radical and H atom may not lie in the same plane the manufacture of ordinary phenol-aldehyde- I resins." '76 seconcuyytherormation or absence or am tion of in'solubles may be related to the aldehyde used and the ratio of aldehyde, particularly formaldehyde, insofar that a slight variation may, under circumstances not understandable, produce insolubilization. The formation of the insoluble resin is apparently very sensitive to the quantity of formaldehyde employed and a slight increase in the proportion of formaldehyde may lead to the formation of insoluble gel lumps. The cause of insoluble resin formation is not clear, and nothing is known as to the structure of these resins.

All that has been said previously herein as regards resin fication has avoided the s ecific reference to activity of a methylene hydrogen atom. Actually there is a possibilitythat under some drastic conditions cross-linking may take place through formaldehyde addition to the methylene bridge, or some other reaction involving a methylene hydrogen atom.

Finally, there is some evidence that, although the meta positions are not ordinarily reactive, possibly at times methylol groups or the like are formed at the meta positions; and if this were the case it may be a suitable explanation of abnormal cross-linking.

. Reactivity of a resin towards excess aldehyde, for instance formaldehyde, is not to be taken as a criterion of rejection for use as a reactant. In other words, a phenol-aldehyde resin which is thermoplastic and solvent-soluble, particularly if xylene-soluble, is perfectly satisfactory even though retreatment with more aldehyde may change its characteristics markedly in regard to both fusibility and solubility. Stated another way, as far as resins obtained from difunctional phenols are concerned, they may be either formaldehyde-resistant or not formaldehyde-resistant.

Referring again to the resins herein contemplated as reactants, it is to be noted that they are thermoplastic phenol-aldehyde resins derived from difunctional phenols and are clearly distinguished from Novolaks or resoles. When these resins are produced from difunctional phenols and some of the higher aliphatic aldehydes, such as acetaldehyde, the resultant is often a comparatively soft or pitchlike resin at ordinary temperature. Such resins become comparatively fl uid at 110 to 165 C. as a rule and thus canloe readily oxyalkylated, preferably oxyethylated, without the use of a solvent.

Reference has been made to the use of the word fusible. Ordinarily a thermoplastic resin is identified as one which can be heated repeatedly and still not lose its thermoplasticity. It is recognized, however, that one may have a resin which is initially thermoplastic but on repeated heating may become insoluble in an organic solvent, or at least no longer thermoplastic, due to the fact that certain changes take place very slowly. As far as the present invention is concerned, it is obvious that a resin to be suitable need only be sufficiently fusible to permit processing to produce our oxyalkylated products and not yield insolubles or cause insolubilization or gel formation, or rubberiness, as previously described. Thus resins which are, strictly speaking, fusible but not necessarily thermoplastic in the most rigid sense that such terminology would be applied to the mechanical properties of a resin, are useful intermediates. The bulk of all fusible resins of the kind herein described are soluble resins, herein employed as reactants, are waterdnsoluble, or have no appreciable hydrophile properties. The hydrophile property is introduced by oxyalkylation. In the hereto appended claims and elsewhere the expression water-insoluble is used to point out this characteristic of the resins used.

In the manufacture of compounds herein employed, particularly for demulsification, it is obvious that the resins can be obtained by one of a number of procedures. In the first place, suitable resins are marketed by a number of companies and can be purchased in the open market; in the second place, there are a wealth of examples of suitable resins described in the literature. The third procedure is to follow the directions of the present application.

The polyhydric reactants, i. e., the oxyalkyla-v tion-susceptible, water-insoluble, organic solventsoluble, fusible, phenol-aldehyde resins derived from difunctional phenols, used as intermediates to produce the products used in accordance with the invention, are exemplified by Examples Nos. la through 1030. of our Patent 2,499,370, granted March '7, 1950, and reference is made to that patent for examples of the oxyalkylated resins used as intermediates.

Previous reference has been made to the use of a single phenol as herein specified, or a single reactive aldehyde, or a single oxyalkylating agent. Obviously, mixtures of reactants may be employed, as for example a mixture of para-butylphenol and para-amylphenol, or a mixture of para-butylphenol and para-hexylphenol, or parabutylphenol and para-phenylphenol. It is extremely difiicult to depict the structure of a resin derived from a single phenol. When mixtures of phenols are used, even in equimolar proportions, the structure of the resin is even more indeterminable. In other words, a mixture involving para-butylphenol and para-amylphenol might have an alternation of the two nuclei or one might have a series of butylated nuclei and then a series of amylated nuclei. If a mixture of aldehydes is employed, for instance, acetaldehyde and butyraldehyde, or acetaldehyde and formaldehyde, or benzaldehyde and acetaldehyde, the final structure of the resin becomes even more complicated and possibly depends on the relative reactivity of the aldehydes. For that matter, one might be producing simultaneously two different resins, in what would actually be a mechanical mixture, although such mixture might exhibit some unique properties as compared with a mixture of the same two resins prepared separately. Similarly, as has been suggested, one might use a combination of oxyalkylating agents; for instance, one might partially oxyalkylate with ethylene oxide and then finish off with propylene oxide. It is understood that the oxyalkylated derivatives of such resins, derived from such plurality of reactants, instead of being limited to a single reactant from each of the three classes, is contemplated and here included for the reason that they are obvious variants.

PART 2 Having obtained a suitable resin of the kind described, such resin is subjected to treatment with a low molal reactive alpha-beta olefin oxide so as to render the product distinctly hydrophile in nature as indicated by the fact that it becomes self-emulsifiable or miscible or soluble in waterf 'or""seli dispersible, or: emulsifying properties" Theolefin. oxides employed are char aeterize'ds-by-the: fact that they contain-not over 4+?carbon' atoms and areselectedfrom the. class consisting of ethylene oxide, propylene oxide, butylene oxide,'glycide, and methylglycide. 5 Glycide may be, of course, considered as'a hydroxy propylene oxide andlmethyl glycide 'asrahyidroxy butylene oxide. In. any event, howevenall such reactants 'contain' the reactiveethylene oxide ring. and maybe best considered as derivatives of or substituted ethylene oxides. The solubilizingeffect of the oxide'is directly proportional" to the percentage of oxygen present, or specifically, to'thepxygen-earbon ratio.

-..In:ethylene"oxide, the oxygen-carbon ratio is 1:2. In glycide,'it is 2:3," and in methyl'glycide, 1:2: In: suchcompounds, the ratio is very favorableto the Iproduction'of hydrophile orsurfaceactive properties. However, the ratio, in propylene oxide, is 1:3, and in butylene oxide,'1:4i. Ob viously, such latter two reactants aresatis'fac torily employed'only where the resin composition ls'suchas to make incorporation of the desired property practical. In other cases, they may produce marginally satisfactory derivatives, or even unsatisfactory derivatives. They are usable in conjunctionwith the three more favorable alkylene oxides in all cases. For instance, after one or several propylene oxideor butylene oxide molecules have been attached to the resin molecule; oxyalkylation may be satisfactorily continued using'the more favorable members oi the'class.

to produce the desired hydrophile product. Used alone, these two reagents may'in some cases fail to produce sufiiciently hydrophile derivatives because 0f"their're1ative1y low oxy en-carbon ratios.

' Thus, ethylene oxide lsimuch more 'efie'ctive than propylene oxide, and propylene oxide is more efiective than butylene: oxide. Hydroxy propylene oxide (glycide) is more 'efiecive than propylene oxide. Similarly, hydroxy butylene oxide (methyl glycide) is more effective than butylene oxide. cheapest alkylene oxide available and is reactive, its use is definitely advantageous; and especially in-light of'its high oxygen. content. Propylene oxide is-less reactive than ethylene oxide, and

Since ethylene oxide is the butylene oxide is definitely, less reactivethan' be 'conducted'with or without pressure-i. e.,- from zero pressure to approximately 200 or even300 pounds gauge pressure (pounds per square inch). In a general way, the method employed is substantialy the same procedure as used for oxyalky'l'ation of other organic materials having 'reactive phenolic groups.

. It may be necessary to allow forthe acidity of! a resin in, determining the amount of al-' catalyst to .be added in .oxyalkylatiom. For

sov

lnstancepifa nonvolatile strong acidsuch as sulE-ri furic acid is used. torcatalyze the .resinification reaction, presumably after being converted into asulfonic acid; it may be necessary and is usually advantageousto add an amount of alkali equal ethyleneglycol diethylether, or the like, although with'many resins, the oxyalkylation proceeds satisf'actorily without a solvent. Since xylene is cheap'and maybe permitted to be present in the finalproduct used as a demulsifier, itis our pref: erence to use xylene. the manufacture of products from low-stage'res ins, i. e, 01"3 and up to and including 7 units per molecule.

It'a x lene solutionis used in an autoclave as hereinafter indicated, the pressure readin s of course represent total pressure; that is, the combined' pressure due to xylene and also due to ethyleneoxide or wh'ateverother oxyalkylatlng agent is used. Under such circumstances it may bejneces ary at times to use substantial pressures to obtain effective results; for instance, pressures up to 300 pounds along with correspondingly high temperatures. if required.

Howeven'even in the instance of high-melting resins. a solvent such as xylene can be eliminated in either one of two ways: After the introduction of approximately 2 or 3 moles of ethylene oxide;-

'rerexample, per phenolic nucleus. there is a de'fi nite dro'pin thehardness and melting point of the resin.- At this stage, if xylene or a similarsolvent has'been added it can be eliminated by distillati'o'riiv'acuum distillation if desired) and the sub seouent intermediate, being comparatively soft and solvent-free, .can be reacted further in the usual manner with-ethylene oxide or some other su table reactant.

Another procedure is to continue the reaction to completion with such solvent present and then eliminate the solvent by distillation in the cus-. tom ary' manner.

Another-suitable procedure is to use pro ylene oxide or butylene oxide as a solvent as well as a reactant in the earlier stages along with ethylene oxide, for instance, by dissolving the powdered resin inpropylene oxide even though oxyalkylation is. taking place to a greater or lesser degree; After asolut on hasbeen obtained whichrepre sents the original resin dissolved in propylene oxide or butylene oxide, or'a mixture which ineludes the oxyalkylated product, ethylene oxide is added to-react with the liquid mass until hydro phileproperties are obtained. Since ethylene ox-'- ide is more reactive than propylene oxide or'butylens-oxide, the final product may contain some unreacted propylene oxide or butylene oxide which. can be. eliminated by volatilization or dis tillationin-any suitable manner. Attentionis directed to the fact thatthe resins hereindescribed must be fusible or soluble in--, an organic solvent. Fusibleresins invariably are soluble in one or more organic solvents such as those mentioned elsewhere herein. It is to be emphasized, however, that the organic solvent employed to: indicate or assure that the resin".. meets this requirement need not be the oneused in..oxyalkylation.. Indeed,solv.e nts which .aresus- This is particularly trueir'r ceptible to oxyalkylation are included in this group of organic solvents. Examples of such solvents are alcohols and alcohol-ethers. However, where a resin is soluble in an organic solvent, there are usually available other organic solvents which are not susceptible to oxyalkylation, useful for the oxyalkylation step. In any event, the organic solvent-soluble resin can be finely powdered, for instance to 100 to 200 mesh, and a slurry or suspension prepared in xylene or the like, and subjected to oxyalkylation. The fact that the resin is soluble in an organic solvent or the fact that it is fusible means that it consists of separate molecules. Phenol-aldehyde resins'of the type herein specified possess reactive hydroxyl groups and are oxyalkylation susceptible.

Considerable of what is said immediately hereinafter is concerned with ability to vary the hydrophile properties of the hydroxylated intermediate reactants from minimum hydrophile properties to maximum hydrophile properties. Such properties in turn, of course, are effected subsequently by the acid employed for esterifi cation and the quantitative nature of the esterification itself, i. e., whether it is total or partial. It may be well, however, to point out what has been said elsewhere in regard to the hydroxylated intermediate reactants. See, for example, our co-pending applications, Serial Nos. 8,730 and 8,731, both filed February 16, 1948 (both now abandoned), and Serial No. 42,133, filed August 2, 1948 (now abandoned), and Serial No. 42,134, filed August 2, 1948 (now abandoned). The reason is that the esterification, repending on the acid selected, may vary the hydrophile-hydrophobe balance in one direction or the other, and also invariably causes the development of some property which makes it inherently different from the two reactants from which the derivative ester is obtained.

Referring to the hydrophile hydroxylated intermediates, even more remarkable and equally difficult to explain, are the versatility and the utility of these compounds considered as chemical reactants as one goes from minimum hydrophile property to ultimate maximum hydrophile property. For instance, minimum hydrophile property may be described roughly as the point where two ethyleneoxy radicals or moderately in excess thereof are introduced per phenolic hydroxyl. Such minimum hydrophile property or sub-surface-activity or minimum surface-activity means that the product shows at least emplsifying properties or self-dispersion in cold or even in warm distilled water to 40 C.) in concentrations of 0.5% to 5.0%. These materials are generally more soluble in cold Water than warm water, and may even by very insoluble in boiling water. Moderately high temperatures aid in reducing the viscosity of the solute under examination. Sometimes if one continues to shake a hot solution, even though cloudy or containing an insoluble phase, one finds that solution takes place to give a homogeneous phase as the mixture cools. Such selfdispersion tests are conducted in the absence of an insoluble solvent.

When the hydrophile-hydrophobe balance is above the indicated minimum (2 moles of ethylene oxide per phenolic nucleus or the equivalent) but insufiicient to give a so] as described immediately preceding, then, and in that event hydrophile properties are indicated by the fact that one can produce an emulsion by having present 10% to 50% of an inert solvent such as xylene. All that one need to do is to have a xylene solution within the range of 50 to parts by weight of oxyalkylated derivatives and 50 to 10 parts by weight of xylene and mix such solution with one, two or three times its volume of distilled water and shake vigorously so as to obtain an emulsion which may be of the oil-inwater type or the water-in-oil type (usually the former) but, in any event, is due to the hydrophile-hydrophobe balance of the oxyalkylated derivative. We prefer simply to use the xylene diluted derivatives, which are described elsewhere, for this "test rather than evaporate the solvent and employ any more elaborate tests, if the solubility is not sufiicient to permit the simple sol test in water previously noted.

If the product is not readily water soluble it may be dissolved in ethyl or methyl alcohol, ethylene glycol diethylether, or diethylene glycol diethylether, with a little acetone added if required, making a rather concentrated solution, for instance 40% to 50%, and then adding enough of the concentrated alcoholic or equivalent solution to give the previously suggested 0.5% to 5.0% strength solution. If the product is selfdispersing (i. e., if the oxyalkylated product is a liquid or a liquid solution self-emulsifiable), such sol or dispersion is referred to as at least semi-stable in the sense that sols, emulsions, or dispersions prepared are relatively stable, if they remain at least for some period of time, for instance 30 minutes to two hours, before showing any marked separation. Such tests are conducted at room temperature (22 C.). Needless to say, a test can be made in presence of an insoluble solvent such as 5% to 15% of xylene, as noted in previous examples. If such mixture, i. e., containing a water-insoluble solvent, is at least semi-stable, obviously the solvent-free product would be even more so. Surface-activity representing an advanced hydrophile-hydrophobe balance can also be determined by the use of conventional measurements hereinafter described. One outstanding characteristic property indicating surface-activity in a material is the ability to form a permanent foam to dilute aqueous solution, for example, less than 0.5%, when in the higher oxyalkylated stage, and to form an emulsion in the lower and intermediate stages of oxyalkylation.

Allowance must be made for the presence of a solvent in the final product in relation to the hydrophile properties of the final product. The principle involved in the manufacture of the herein contemplated compounds for use as polyhydric reactants, is based on the conversion of a hydrophobe or non-hydrophile compound or mixture of compounds into products which are distinctly hydrophile, at least to the extent that they have emulsifying properties or are selfemulsifying; that is, when shaken with water they produce stable or semi-stable suspensions, or, in the presence of a water-insoluble solvent, such as xylene, an emulsion. In demulsification, it is sometimes preferable to use a product having markedly enhanced hydrophile properties over and above the initial stage of self-emulsifiability, although we have found that with products of the type used herein, most efiicacious results are obtained with products which do not have hydrophile properties beyond the stage of self-dispersibility.

iamfejooo More highly oxyalkylated resins give colloidal solutions or sols which show typical properties comparable to ordinary surface-active agents. Such conventional surface-activity may be measured'by determining the surface tension and the interfacial tension against parafiin oil or the like. At the initial and. lower stages of oxyalkylation, surface-activity is not suitably determined in this same manner but one may employ an emulsification test. Emulsions come into existence as a rule through the presence of a surface-active emulsifying agent. Some surfaceactive emulsifying agents such as mahogany soap may produce a water-in-oil emulsion or an oil-in-water emulsion depending upon the ratio of the two phases, degree of agitation, concentration of emulsifying agent, etc.

The same is true in regard to the oxyalkylated resins-herein specified; particularly in the. lower stage of, oxyalkylation, the so-called subsurface-active. stage. The'surface-active propertiesare readily demonstrated by. producing a xylenewater emulsion. A suitable procedure is as follows: Theoxyalkylated resin is dissolved in' an equal weight of'xylene. Such 50-50 solution is then mixed with 1-3 volumes of water and shaken to produce an emulsion. The amount of xylene is invariably sufiicient to reduce even atacky resinous product to a solution which is readily dispersible. The emulsions so produced are usually xylene-in-water emulsions (oil-in-water type) particularly when the'amount of distilled water used is at least slightly in excess of the; volume of xylene solution and also if. shaken vigorously. At times, particularly in the lowest stage of 'oxyalkylation, one may obtain awater-in-xylene emulsion (water-in-oil type) which is apt to reverse on more vigorous shaking and further. dilution with water;

If in doubt as to this property, comparison with. a resinobtained from para-tertiary butylphenol and formaldehyde (ratio 1 part phenol to 1.1 formaldehyde) using an acid catalyst and thenfollowed by oxyalkylation using. 2 'moles of ethylene oxide for-each vphenolic'h'ydrioxyl,v is helpful, Such resin priorto oxyalkylation has a molecular weight indicating about 4 /2 units per resin molecule. Such resin,v when diluted with an equalweight of xylene,.will serve to illustrate the,above emulsification .test.

In a few instances, the resin may not be sufii ciently solublein xylene alone but mayrequire the additionof some ethylene glycoldiethylether as described elsewhere. It is understood that such mixture, or any other similar mixture, is considered the equivalent of xylene for the purpose of this test.

In many cases,- there is no doubt as to the presence or absenceof hydrophile or surfaceactive characteristics in the polyhydric reactants used in accordance with this invention. They dissolve or disperse in water; and such dispersions foam readily. With borderline cases, i. e., those which show only incipient hydrophile orsurface-active property (sub-surface-activity) tests for emulsifying properties or self-dispersibility are useful. The fact that a reagent is capableof producing a dispersion inwater is proof. that it is distinctly hydrophile. In doubtful cases, comparison can be made with the butylphenol-formaldehyde resin analog wherein 2 moles .of ethylene oxide have been introduced for each phenolic nucleus.

The presence of xylene or an equivalent water- 2 8 insoluble solvent may mask the point at which a solvent-free'product on mere dilutio'n in a test tube exhibits self er'nulsification. Forthis reason; if it is desirable to determine the approximate point where self-emulsification begins, then it' is better to elniinate the xylene or equivalent from a small portion of thereaction' mixture and test such portion. In somecases, such xylene-free resultant may shown" initial or'inc'ipient hydra 'hile properties, whereas in presence of xylene such properties would not benote'd. In other cases, the first objectiveindicati'on of" hydro phile properties be'thecapacity of'thema' terial' to emulsify an" insolubleisolve'rit" such as xylene. It isi'to'beemphasiz'ed'that hydrophile properties herein referred to are such as those exhibited by incipient self-emulsifi-cation or the pres nce of emulsifying properties go through the rangeof homogeneous dispe'rsibility or admixture with water' even in" presence'of added water-insoluble solvent and minor pmpor. tions of common electrolytes as occur in oil field brines'.

Elsewhere, it is pointed out that an emulsifi cation test may be used to determine rangesof surface-activity and that such emulsification tests'einploy a xylene solution. Stated another way, it is really immaterial whether a xylene solution produces a sol or whether itmerely produe-es an emulsion.

In light-of what'has been said previously in regard to the variation-of range of hydrophile: properties, and alsoin lightof what has been said as tothe variation in the effectivenessof various alkylene oxides, and most particularly of j all ethylene oxide, to introduce hydrophile char-. acter, it becomes obvious that there is a wide; variation in the amount of alkylene oxide em-. ployed, as lon'gas it is at'least 2moles perphenolic nucleus, for producingproductsuseful for the practice of this invention. Another vari-- ati'on is the molecular size of the resin chain re suiting from reaction between the difunctional; phenol and the aldehyde such as formaldehyde}. It is well known that thesize and nature or struc-. ture of t P resin polymer obtained varies some-- what with the conditions of reaction, the proportions of reactants, the nature 'of the catalyst, etc;.

Based on molecular weight determinations,. most of the resins prepared as herein described,

particularly in the absenceof a secondary heat ing step, contain 3 to 6 or '7 phenolic nuclei with approximatelye .or'5% nuclei as an average. More drastic conditions of resinification yield resins of greater chain length. Such more intensive resinification is a conventional procedure and may be employed if desired Molecular weight, of course, is measured by anysuitable procedure, particularly by cryoscopic methods; but usingthe same reactants and using more drastic conditions of resinification one usually finds that higher molecular weights are indicated by higher melting points of the resins and atendency to decreased solubility. See what has been said elsewhere herein in regard to a secondary step involving the heating of a resin with or without the use of vacuum.

We have previously pointed out that either an alkaline or acid catalyst is advantageously used in preparing the resin. A combination of catalysts is sometimes used in two stages; for in-' stance, an alkaline catalyst is sometimes employed in a first stage, followed by neutralization and addition of a small amount of acid catalyst in a second stage. It is generally believed that even in the presence of an alkaline catalyst, the number of moles of aldehyde, such as formaldehyde, must be greater than the moles of phenol employed in order to introduce methylol groups in the intermediate stage. There is no indication that such groups appear in the final resin if prepared by the use of an acid catalyst. It is possible that such groups may appear in the finished resins prepared solely with an alkaline catalyst; but we have never been able to confirm this fact in an examination of a large number of resins prepared by ourselves. Our preference, however, is to use an acid-catalyzed resin, particularly employing a formaldehyde-to-phenol ratio of 0.95 to 1.20 and, as far as we have been able to determine, such resins are free from methylol groups. As a matter of fact, it is probable that in acid-catalyzed resinifications, the methylol structure may appear only momentarily at the very beginning of the reaction and in all probability is converted at once into a more complex structure during the intermediate stage.

One procedure which can be employed in the use of a new resin to prepare polyhydric reactants for use in the preparation of compounds employed in the present invention, is to determine the hydroxyl value by the Verley-Btilsing method or its equivalent. The resin as such, or in the form of a solution as described, is then treated with ethylene oxide in presence of 0.5% to 2% of sodium methylate as a catalyst in stepwise fashion. The conditions of reaction, as far as timeor per cent are concerned, are Within the range previously indicated. With suitable agitation the ethylene oxide, if added in molecular proportion, combines within a comparatively short time, for instance a few minutes to 2 to 6 hours, but in some instances requires as much as 8 to 24 hours. A useful temperature range is from 125 to 225 C. The completion of the reaction of each addition of ethylene oxide in stepwise fashion is usually indicated by the reduction or elimination of pressure. An amount conveniently used for each addition is generally equivalent to a mole or two moles of .ethylene oxide per hydroxyl radical. When the amount of ethylene oxide added is equivalent to approximately 50% by weight of the original resin, a sample is tested for incipient hydrophile properties by simply shaking up in water as is, or after the elimination of the solvent if a solvent is present. The amount of ethylene oxide used to obtain a useful demulsifying agent as a rule varies from 70% by weight of the original resin to as much as five or six times the weight of the original resin. In the case of a resin derived from para-tertiary butylphenol, as little as 50% by weight of ethylene oxide may give suitable solubility. With propylene oxide even a greater molecular proportion is required and sometimes a resultant of only limited hydrophile properties is obtainable. The same is true to even a greater extent with butylene oxide. The hydroxylated alkylene oxides are more effective in solubilizing properties than the comparable compounds in which no hydroxyl is present.

Attention is directed to the fact that in the subsequent examples reference is made to the stepwise addition of the alkylene oxide, such as ethylene oxide. It is understod, of course, there is no objection to the continuous addition of alkylene oxide until the desired stage of reaction is reached.- In fact there may be less of a hazard involved and it is often advantageous to add the alkylene oxide slowly in a continuous stream and in such amount as to avoid exceeding the higher pressures noted in the various examples or elsewhere.

It may be well to emphasize the fact that when resins are produced from difunctional phenols and some of the higher aliphatic aldehydes, such as acetaldehyde, the resultant is a comparatively soft or pitch-like resin at ordinary temperatures. Such resins become comparatively fluid at to C. as a rule and thus can be readily oxyalkylated, preferably oxyethylated, without the use of a solvent.

What has been said previously is not intended to suggest that any experimentation is necessary to determine the degree of oxyalkylation and particularly oxyethylation. What has been said previously is submitted primarily to emphasize the fact that these remarkable oxyalkylated resins having surface activity show unusual properties as the hydrophile character varies from a minimum to an ultimate maximum. One should not underestimate the utility of any of these polyhydric alcohols in a surface-active or subsurface-active range without examining them by reaction with a number of the typical acids herein described and subsequently examining the resultant for utility, either in demulsification or in some other art or industry as referred to elsewhere, or as a reactant for the manufacture of more complicated derivatives. A few simple laboratory tests which can be conducted in a routine manner will usually give all the information that is required.

For instance, a simple rule to follow is to prepare a resin having at least three phenolic nuclei and being organic solvent-soluble. Oxyethylate such resin, using the following four ratios of moles of ethylene oxide per phenolic unit equivalent: 2 to 1; 6 to 1; 10 to 1; and 15 to 1. From a sample of each product remove any solvent that may be present, such as xylene. Prepare 0.5% and 5.0% solutions in distilled water, as previously indicated. A mere examination of such series will generally reveal an approximate range of minimum hydrophile character, moderate hydrophile character, and maximum hydrophile character. If the 2 to 1 ratio does not show minimum hydrophile character by test of the solventfree product, then one should test its capacity to form an emulsion when admixed with xylene or other insoluble solvent. If neither test shows the required minimum hydrophile property, repetition using 2 to 4 moles per phenolic nucleus will serve. Moderate hydrophile character should be shown by either the 6 to 1 or 10 to 1 ratio. Such moderate hydrophile character is indicated by the fact that the sol in distilled Water within the previously mentioned concentration range is a permanent translucent sol when viewed in a comparatively thin layer, for instance the depth of a test tube. Ultimate hydrophile character is usually shown. at the 15 to 1 ratio test in that adding a small amount of an insoluble solvent, for instance 5% of xylene, yields a product which will give, at least temporarily, a transparent or translucent sol of the kind just described. The formation of a permanent foam, when a 0.5% to 5.0% aqueous solution is shaken, is an excellent test for surface activity. Previous reference has been made to the fact that other oxyalkylating agents may require the use of increased amounts of alkylene oxide. However, if one does not even care to go to the trouble of calculating molecular weights, one can simply arbitrarily prepare compounds containing ethyl ene oxide equivalent to about 50% to 75% by weight, for example 65% by weight, of the resin to be oxyethylated; a second example using approximately 200% to 300% by weight, and a third example using about 500% to 750% by weight, to explore the range of hydroph-ile hydrophobe balance.

A practical examination of the factor of oxyalkylation level can be 'r'nade by a very simple test using a pilot plant autoclave having a capacity of about to gallons as hereinafter described. Such laboratory-prepared routine compounds can then be tested for solubility and, generally speaking, this is all that is required to give a suitable variety covering the hydrophile-hy'drophobe range. All these tests,- as stated, are intended to be routine tests and nothing more. They are intended to teach a person, even though unskilled in oxyethylation or oxyalkylation, how to prepare in a perfectly arbitrary manner, a series of compou'nds illustrating the hydrophile-hydrophoo'e range. V

If one purchases a thermoplastic or fusible resin on the open market selected from a suitable number which are available, one might have to make certain determinations in order to make the quickest approach to the appropriate oxyalk'ylation range. For instance, one should know 'F H l' c -o m=1 to 13; or even more) is given approximately by the formula: (mol; wt. of phenol -2) plus incl. wt. of methylene or substituted methylene radical. The molecular weight of the resin would be n times the value for the internal limit plus the values for the terminal units. The left-hand terminal unit of the above structural formula, it will be seen, is identical with the recurring internal unit except that it has one extra hydrogen. The right' hand terminal unit lacks the methylene bridge element. Using one internal unit of a resin as the basic element, a resins molecular weight is given approximately by taking (n plus 2) times the weight of the internal element. Where the resin molecule has only 3 phenolic nuclei as in the structure shown, this calculation will be in error by several per cent; but as it grows larger, to contain 6, 9, or 12 phenolic nuclei, the formula comes to be more than satisfactory. Using such an approximate weight, one need only introduce, for example, two molal weights of ethylene oxide or slightly more; per phenolic nucleus, to produce a product of minimal hydrophi-le character. Further oxyalkylation gives enhanced hydrophile character. Although we have prepared and tested a large number of oxyethylated products of the type described herein, we have found no instance where the use of less than 2 moles of ethylene oxide per phenolic nucleus gave desirable products.

Examples 1?) through 181), and the tables which appear in columns 51 through 56 of our said Patent 2,499,370 illustrate oxyalkylation products from resins which are useful as intermediates for producing the esterified products used in accordance with the present application, uch examples giving exact and complete details for carrying out the oxyalkylation procedure.

The resins, prior to oxyalkyiation, vary from tacky, viscous liquids to hard, high-melting solids. Their color varies from a light yellow through amber, to a deep red or even almost black. In the manufacture of resins, particularly hard resins, as the reaction progresses the reaction mass frequently goes through a liquid state to a sub-resinous or semi-resinous state, often characterized by being tacky or sticky, to a final complete resin. As the resin is subjected to oxya-lkylation these same physical changes tend to take place in reverse. If one starts with a solid resin, oxyalkylation tends to make it tacky or semi-resinous and further oxyalkylation makes the tackiness disappear and changes the product to a liquid. Thus, as the resin is oxyalkylated it decreases in viscosity, that is, becomes more liquid or changes from a solid to a liquid, particularly when it is converted to the water-dispersible or water-soluble stage. The color of the oxyalkylated derivative is usually considerably lighter than the original product from which it is made, varying from a pale straw color to an amber or reddish amber. The viscosity usually varies from that of an oil, like castor oil, to that of a thick viscous sirup. Some products are waxy. The presence of a solvent, such as 15% xylene or the like, thins the viscosity considerably and also reduces the color in dilution. No undue significance need be attached to the color for the reason that ii the same compound is prepared in glass and in iron, the latter usually has somewhat darker color. If the resins are prepared as customarily employed in varnish resin manufacture, i. e. a procedure that excludes the presence of oxygen during the resinification and subsequent cooling of the resin, then of course the initial resin is much lighter in color. We have employed some resins which initially are almost water-white and also yield a lighter colored final product.

Actually, in considering the ratio of alkylene oxide to add, and we have previously pointed out that this can be pie-determined using laboratory tests, it is our actual preference from a practical standpoint to make tests on a small pilot plant scale. Our reason for so doing is that we make one run, and only one, and that we have a con1- plete series which shows the progressive effect of introducing the oxyalkylating agent, for instance, the e'thyleneoxy radicals. Our preferred procedure is as follows: We prepare a suitable resin, or for that matter, purchase it in the open market. We employ 8 pounds of resin and 4 pounds of xylene and place the resin and xylene in a suitable autoclave with an open reflux condenser. We prefer to heat and stir until the solution is complete. We have pointed out that soft resins which are fluidor semi-fluid can be readily prepared in; various Ways, such as the use of ortho-tertiary amylphenol, ortho-hydroxydiphenyl, ortho-decylphenol, or by the use of higher molecular weight aldehydes than formaldehyde. If such resins are used, a solvent need not be added but may be added as a matter of convenience or for comparison, if desired. We then add a catalyst, for instance, 2% of caustic soda, in the form of a 20% to 30% solution, and remove the water of solution or formation. We then shut off the reflux condenser and use the equipment as an autoclave only, and oxyethylate until a total of 60 pounds of ethylene oxide have been added, equivalent to 750% of the original resin. We prefer a temperature of about 150 C. to 175 C. We also take samples at intermediate points as indicated in the following table: I

Oxyethylation to 750% can usually be completed within 30 hours and frequently more quickly.

The samples taken are rather small, for instance, 2 to 4 ounces, so that no correction need be made in regard to the residual reaction mass. Each sample is divided in two. One-half the sample is placed in an evaporating dish o the steam bath overnight so as to eliminate the xylene. Then 1.5% solutions are prepared from both series of samples, 1. e., the series with xylene present and the series with xylene removed.

Mere visual examination of any samples in solution may be sufiicient to indicate hydrophile character or surface activity, i. e., the product is soluble, forming a colloidal sol, or the aqueous solution foams or shows emulsifying property.

All these properties are related through adsorption at the interface, for example, a gas-liquid interface or a liquid-liquid interface. If desired, surface activity can be measured in any one of the usual ways using a Du Nouy tensiometer or dropping pipette, or any other procedure for measuring interfacial tension. Such tests are conventional and require no further description. Any compound having sub-surface-activity, and all derived from the same resin and oxyalkylated to a greater extent, i. e., those having a greater proportion of alkylene oxide, are useful as polyhydric reactants for the practice of this invention.

. Another reason why we prefer to use a pilot plant test of the kind above described is that we can use the same procedure to evaluate tolerance toward a trifunctional phenol such as hydroxybenzene or metacresol satisfactorily. Previous reference has been made to the fact that one can conduct a laboratory scale test which will indicate whether or not a resin, although soluble in solvent, will yield an insoluble rubbery product, i. e., a product which is neither hydrophile nor surface-active, upon oxyethylation, particulajrly extensive oxyethylation. It is also obvious that one may have a solvent-soluble resin derived from a mixture of phenols having present 1% or 2% of a trifunctional phenol which will result in a insoluble rubber at the ultimate stages of oxyethylation but not in the earlier stages. In other words, with resins from some such phenols, addition of 2 or 3 moles of the oxyalkylating agent per phenolic nucleus, partioularly ethylene oxide, gives a surface-active reactant which is perfectly satisfactory, while more extensive oxyethylation yields an insoluble rubber, that is, an unsuitable reactant. It is obvious that this present procedure of evaluating trifunctional phenol tolerance is more suitable than the previous procedure.

It *may be well to call attention to one result which may be noted in a long drawn-out oxyalkylation, particularly oxyethylation, which would not appear in a normally conducted reaction. Reference has been made to cross-linking and its effect on solubility and also the fact that, if carried far enough, it causes incipient stringiness, then pronounced stringiness, usually followed by a semi-rubbery or rubbery stage. Incipient stringiness, or even pronounced stringiness, or even the tendency toward a rubbery stage, is not objectionable so long as the final product is still hydrophile and at least subsurface-active. Such material frequently is best mixed with a polar solvent, such as alcohol or the like, and preferably an alcoholic solution is used. The point which we want to make here, however, is this: Stringiness or rubberization at this stage may possibly be the re-- sult of etherification. Obviously if a difunctional phenol and an aldehyde produce a noncross-linked resin molecule and if such molecule is oxyalkylated so as to introduce a plurality of hydroxyl groups in each molecule, then and in that event if subsequent therification takes place, one is going to obtain cross-linking in the same general way that one would obtain crosslinking in other resinification reactions. Ordinarily there is little or no tendency toward etherification during the oxyalkylation step. If it does take place at all, it is only to an insignificant and undetectable degree. However, suppose that a certain weight of resin is treated with an equal weight of, or twice its weight of, ethylene oxide. This may be done in a comparatively short time, for instance, at or C. in 4 to 8 hours, or even less. On the other hand, if in an exploratory reaction, such as the kind previously described, the ethylene oxide were added extremely slowly in order to take stepwise samples, so that the reaction required 4 or 5 times as long to introduce an equal amount of ethylene oxide employing the same temperature, then etheriiication might cause stringiness or a suggestion of rubberiness. For this reason if in an exploratory experiment of the kind previously described there appears to be any stringiness or rubberiness, it may be well to repeat the experiment and reach the intermediate stage of oxyalkylation as rapidly as possible and then proceed slowly beyond this intermediate stage. The entire purpose of this modified procedure is to cut down the time of reaction so as to avoid etherification if it be caused by the extended time period.

It may be well to note one perculiar reaction sometimes noted in the course of oxyalkylation, particularly oxyethylation, of the thermoplastic resins herein described. This effect is noted in a case where a thermoplastic resin has been oxy- 27 2'8 alkylated, for instance, oxyethylated, until it ployedshould be non-reactive to the alkylene oxgives a perfectly clear solution, even in the preside employed. This limitation does not apply to once of some accompanying water-insoluble solsolvents used in cryoscopic determinations for vent such as 16% to 15% of Xylene. Further obvious reasons. Attention is directed to the fact oxyalkylation, particularly oxyethylation, may 5 that various organic solvents may be employed to then yield a product which, instead of giving a verify that the resin is organic solvent-soluble. clear solution as previously, gives a very milky Such solubility test merely characterizes the ressolution suggesting that some marked change in. The particular solvent used in such test may has taken place. One explanation of the above not be suitable for a molecular weight deterchange is that the structural unit indicated in mination and, likewise, the solvent used in deterthe following way where 8n is a fairly large nummining .molecular weight may not be suitable as ber, for instance, 10 to 20, decomposes and an a solvent during oxyalkyl'ation. For solution of oxyalkylated resin representing a lower degree the oxyalkylated compounds, or their derivatives of oxyethylation and a less soluble one, is gena great variety of solvents may be employed, such erated and a cyclic polymer of ethylene oxide is as alcohols, ether alcohols, cresols, phenols, heproduced, indicated thus: tones, esters, etc., alone or with the addition of H513 H(I3H H4 H4 R O(CzH4O)snH nQowmomH-t o2 0 I \OH4C2 l ln This fact, of course, presents no difficulty for water. Some of these are mentioned hereafter. the reason that oxyalkylation can be conducted We prefer the use of benzene or diphenylamine in each instance stepwise, or at a gradual rate, as a solvent in making cryoscopic measurements. and samples taken at short intervals so as to The most satisfactory resins are those which are arrive at a point where optimum surface activity soluble in xylene or the like, rather than those or hydrophile character is obtained if desired; which are soluble only in some other solvent confor products for use as polyhydric reactants in taining elements other than carbon and hydrothe practice of this invention, this is not necesen, for ins ance, oxygen or chlorine. Such solsary and, in fact, may be undesirable, i. e., revents are usually polar, semi-polar, or slightly duce the efiiciency of the product. polar in nature compared with xylene, cymene,

' We do not know to what extent oxyalkylation etc. produces uniform distribution in regard to phe- Reference to y seop e easurement is con.- li hydroxyls present i th resin meme- 1e, cerned with the use of benzene or other suitable In some instances, of course, such distribution comp as a lvent. Such method will show can not be uniform for the reason that we have h v i l resins obtained, f r x p not specified that th molecules of ethylene oxide, 40 from Dare-tertiary emylphenel and formaldefor example, be ad ed in multiples of the units yde in presence of an acid cataly t, will have present in the resin molecule. This may be illusa molecular wei ht indicating 3, 5 r som what trated in the following manner: greater number of structural units per molecule.

Suppose the resin happens to have five phenolic If lnore drastic conditions of resinification are nuclei. If a minimum of two moles of ethylene .5 employed or if such low-stage resin is subj ed id per phenolic 1 1 1 5 a dd d, thi u1d to a vacuum distillation treatment as previously mean an addition of 10 moles of ethylene oxide, described, one obtains a resin of a distinctly but suppose that one added 11 moles of ethylene h r mole ular Weigh Any mole ul r W i h oxide, or 12, or 13, or 14 moles; obviously, even determination used, whether cryoscopic measureassuming the most uniform distribution posment or otherwise, other than the conventional sible, some of the polyethyleneoxy radicals would eryoeeopie One ploying benzene, should be contain 3 ethyleneoxy units and some would conchecked 50 as to insure t at it ves cons stent tain 2. Therefore, it is impossible to specify univalues on such conventional resins as a control. form distribution in regard to the entrance of Fr q en ly all tha i n ry to k n nthe ethylene oxide or other oxyalkylating agent. proximation of the molecular weight ran e s For that matter, if one were to introduce 25 to make a comparison with the dimer obtained moles of ethylene oxide there is no way to be by chemical combination of two moles of the certain that all chains of ethyleneoxy units would same phenol, and one mole of the same aldehyde have 5 units; there might be some having, for under conditions to insure dimerization, As to example, 4 and 6 units, or for that matter 3 or 7 80 the preparation of such dimers from substituted units. Nor is there any basis for assuming that phenols, see Carswell, Phenoplasts, page 31. the number of molecules of the oxyalkylating The increased viscosity, resinous character, and agent added to each of the molecules of the resin decreased solubility, etc., of the higher polymers is the same, or different. Thus, where formulae in comparison with the dimer, frequently are all are given to. illustrate or depict the oxyalkylated that is required to establish that the resin conproducts, distributions of radicalsindicated are tains 3 or more structural units per molecule. to be statistically taken. We have, however, in- Ordinarily, the oxyalkylation is carried out in cluded specific directions and specifications in autoclaves provided with agitators or stirring deregard to the total amount of ethylene oxide, or vices. We have found that the speed of the agita o l am unt of any o er oxy lkyl ing a nt, tion markedly influences the reaction time. In to add. some cases, the change from slow speed agita- In regard to solubility of the resins and the tion, for example, in a laboratory autoclave agitaoxyalkylated compounds, and for that matter tion with a stirrer operating at a speed of 60 to derivatives of the latter, the following should 200 R. P. M., to high speed agitation, with the be noted. In oxyalkylation, any solvent emstirrer operating at .250 to 350 R. P. IVL, reduces this 29 the time required for oxyalkylation by about onehalf to two-thirds. Frequently xylene-soluble products which give insoluble products by procedures employing comparatively slow speed agitation, give suitable hydrophile products when produced by similar procedure but with high speed agitation, as a result, we believe, of the reduction in the time required with consequent elimination or curtailment of opportunity for curing or etherization. Even if the formation of an insoluble product is not involved, it is frequently advantageous to speed up the reaction, thereby reducing production time, by increasing agitating speed. In large scale operations, we have demonstrated that economical manufacturing results from continuous oxyalkylation, that is, an operation in which the alkylene oxide is continuously fed to the reaction vessel, with high speed agitation, i. e., an agitator operating at 250 to 350 R. P. M. Continuous oxyalkylation, other conditions being the same, is more rapid than batch oxyalkylation, but the latter is ordinarily more convenient for laboratory operation.

Previous reference has been made to the fact that in preparing esters or compounds of the kind herein described, particularly adapted for demulsification of water-in-oil emulsions, and for that matter for other purposes, one should make a complete exploration of the wide variation in hydrophobe-hydrophile balance as previously referred to. It has been stated, furthermore, that hydrophobe-hydrophile balance of the oxyalkylated resins is imparted, as far as the range of variation goes, to a greater or lesser extcnt to the herein described derivatives. This means that one employing the present invention should take the choice of the most suitable derivative selected from a number of representative compounds, thus, not only should a variety of resins be prepared exhibiting a variety of oxyalkylations, particularly oxyethylations, but also a variety of derivatives. This can be done conveniently in light of what has been said previously. From a practical standpoint, using pilot plant equipment, for instance, an autoclave having a capacity of approximately three to five gallons. We have made a single run by appropriate selections in which the molal ratio of resin equivalent to ethylene oxide is one to one,

l to 5, l to 10, 1 to 15, and l to 20. Furthermore, in making these particular runs we have used continuous addition of ethylene oxide. In the continuous addition of ethylene oxide we have employed either a cylinder of ethylene oxide without added nitrogen, provided that the pressur of the ethylene oxide was suhiciently great to pass into the autoclave, or also we have used an arrangement which, in essense, was the equivalent of an ethylene oxide cylinder with a means for injecting nitrogen so as to force out the ethylene oxide in the manner of an ordinary seltzer bottle, combined with the means for either weighing the cylinder ormeasuring the ethylene oxid used volumetrically. Such procedure and arrangement for injectingliquids is, of course, conventional. The following data sheets ex-' emplify such operations, 1. e., the combination of both continuous agitation and taking samples so as to give five different variants in oxyethyla tion. In adding ethylene oxide continuously, there is one precaution which must be taken at all times. The addition of ethylene oxide must stop immediately if there is any indication that reaction is stopped or, obviously, if reaction is not started at the beginning of the reaction period. Since the addition of ethylene oxide is invariably an exothermic reaction, whether or not reaction has taken place can be judged in the usual manner by observing (a) temperature rise or drop, if any, (h) amount of cooling water or other means required to dissipate heat of reaction; thus, if there is a temperature drop without the use of cooling water or equivalent, or if there is no rise in temperature without using cooling water control, careful investigation should be made.

In the tables immediately following, we are showing the maximum temperature which is usually the operating temperature. In other words, by experience we have found that if the initial reactants are raised to the indicated temperature and then if ethylene oxide is added slowly, this temperature is maintained by cooling water until the oxyethylation is complete. We have also indicated the maximum pressure that We obtained or the pressure range. Likewise, we have indicated the time required to inject the ethylene oxide as well as a brief note as to the solubility of the product at the end of the oxyethylation period. As one period ends it will be noted we have removed part of the oxyethylated mass to give us derivatives, as therein described; the rest has been subjected to further treatment. All this is apparent by examining the columns headed Starting mix, "Mix at end of reaction, Mix which is removed for sample, and Mix which remains as next starter.

The resins employed are prepared in the manner described in Examples Nos. 1a through 103a of our said Patent 2,499,370 except that instead of being prepared on a laboratory scale they were prepared in 10 to l5-gallon electro-vapor heated synthetic resin pilot plant reactors, as manufactured by the BlaW-Knox Company, Pittsburgh, Pennsylvania, and completely described in their bulletin No. 2687 issued in 1947, with specific reference to specification No. 71-3965.

For convenience, the following tables give the numbers of the examples of our said Patent 2,e99,370 in which the preparation of identical resins on laboratary scale are described. It is understood that in the following examples, the change is one with respect to the size of the operation.

The solvent used in each instance was xylene. This solvent is particularly satisfactory for the reason that it can be removed readily by distillation or vacuum distillation. In these continuous experiments the speed of the stirrer in the autoclave was 250 R. P. M.

In examining the subsequent tables it will be noted that if a comparatively small sample is taken at each stage, for instance, /2 to one gallon, one can proceed through the entire molal stage of l to l, to l to 20, without remaking at any intermediate stage. This is illustrated by Example l04a. In other examples we found it dc;- sirable to take a larger sample, for instanc'eya B-gallon sample, at an intermediate stage. As a result it was necessary in such instances to start with a new resin sample in order to prepare suflicient oxyethylated derivatives illustrating the latter stages. Under such circumstances, of course, the earlier stages which had been previously prepared were by-passed or ignored. This is illustrated in the tables where, obviously, it shows that the starting mix was not removed from a previous sample.

resin: Paratertiaryramylphenol EResinrnadeinpilot plant-sizebatch,-apnroximately25 pounds, corresponding to -3a of Patent 2;499,370'but thishateh designated 104m] Phenol for resin: Nonylp'henol Date, June 18, 1948 Aldehyde for resin: Formaldehyde Mix Which is Mix .Whieh Re- Starting Mix fig ggg of Removed i'o'r mains as N ext Sample Starter Max V Pressure Temp era-' Solubility Lbs. Lbs. Lbs. Lbs. Lbs Lbs. Lbs. I bq Lbs.I Lbs. Lbs Sol- Resz Sol- Res- .Sol- Res- Sol- Resvent in vent in vent in vent. in

First Stage Resin to EtO Molal Ratio 1:1. 14.25 15. 75 0 14. 15.75 4. 0 .3. 3.65 1.0 1059 "12.1 3. 0 80 150 M I Ex. No.104b 1 Second Stage Resin to EtO. Y z s .Molal Ratio 1:5 10. 9 12.1 3. 0 10. 9 12.1 '15. 25 3.'77 4. 17 5. 31 7.13 7.93 9. 94 70 158 2 ST No. 105b Third Stage Resinto EtO. g Molal "Ratio 1:10. 7. 13 7. 93 9. 94 7. 13 7.93 '19. 69 3. 29 3. 68 9. 04 3. 84 4:25 10. 65 173 Ma .FS 'Ex. No.106b I Fourth Stage Resin to EtO I 'Mol al Ratio 1:15 3:84 4. 25 10. 3.84 4. 25 '16. 15 2. 04 2. 21 8. 55 1. 2. 04 7. (i0 220 160 $6 RS 'Ex.'No.'107b Fifth Stage Resin to EtO ...i M01111 Ratio 1:20. 1.80 2.04 7. 60 1.80 2.04 10. 2 $2; QS

No. l 0Sb I,=InsoIub1e. ST=S1ight tendency toward becoming soluble. FS=Fairly soluble. RS=Readily soluble. QS=Quite soluble.

[Resin made in pilot plant size batch, approximately 25 pounds, corresponding to 70a oi'Patent 2,499,370 but this batch designated 109a] Mix Which is Mix Which Restarting Mix figf ggg of Removed for mains as Next Sample Starter Max MM Pressure Tempera- 1i Solubility lbs. sq. in. ture, O. r Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. T bs Sol- 1105- Sol- Res- .Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO Molal Ratio 1:1 1 15. 0 15. .0 0 15. 0 15. 0 3 5. 0 5. 0 1. 0 10. 0 I 10. 0 2. 0 50 150 1% ST Ex. No.109b

Second Stage Resin to EtO. Molal Ratio 1:5- 10 10 2. 0 10 1O 9. 4 2. 72 .2. 72 2. 5,6 7. 27 7. 27 6. 86 100 147 2 DI Ex. No.'110b.-

Third Stage Resin to E t0.. Molal Ratio 1:10. 7.27 7,27 5.86 7. 27 7. 27 13. 7 4. 16 4.10 7.68 3.15 3.15 5.95 125 1% S Ex. No. l1lb Fourth Stage Resin to EtO. Molal Ratio 1:15. 3. 15 3. 15 5. 95 3. 15 3. 15 8. 95 1. 05 1. 05 2. 95 2. 10 2. 10 6. 00 220 174 2% S Ex. No. 112b Fifth Stage Resin to EtO. Molal Ratio 1:20. 2. 10 2. 10 6.00 2. 10 2. l0 8. O0 220 183 VS S.=So11 1ble. ST= Slight tendency toward solubility. DT=Dei1nite tendency toward solubility. VS=Very soluble.

Phenol for resin: Para-octylphenol Date, June 23, 24, 1948 [Resin made in pilot plant size batch, approximately 25 pounds, corresponding to 8a of Patent 2,499,370 but this batch designated 114a.]

Aldehyde for resin: Formaldehyde Date, July 8-13, 1948 Phenol for resin: M enthylphenol VS=Very soluble.

Aldehyde for resin: Formaldehyde Mix Which is Mix Which Re- Starting Mix figg ggg of Removed for mains as Next Sample Starter Max. Max. Time Pressure Tempsrahrs Solubility Lbs. Lbs. Lbq Lbs. Lbs. Lbs Lbs. Lbs. Lb Lbs. Lbs. Ib Sol- Resa Sol- Res- Sol- Resb' Sol- Resvent in vent in vent in vent in First Stage Resin to EtO Molal Ratio 1:1 14.2 15.8 0 14.2 15.8 3. 25 3.1 3.4 0.75 11.1 12.4 2.5 50 150 1H2 NS Ex. No. 1140.....

Second Stage Resin to EtO. Molal Ratio 1:5 11.1 12.4 2.5 11.1 12.4 12.5 7.0 7.82 7. 88 4.1 4.58 4.62 100 171 32 SS Ex. N0. lb.

Third Stage Resin to EtO.. Molal Ratio 1:10. 6.64 7.36 O 6.64 7.36 15.0 120 190 1% 8 Ex. No.116b..-.

Fourth Stage Resin to EtO...- Molal Ratio 1:15- 4.40 4.9 0 4.4 4.9 14.8 400 160 1-4 VS Ex. No. 117b Fifth Stage Resin to M0. Molal Ratio 1:20- 4.1 4.58 4.62 4.1 4.58 18. 52 260 172 34; VS Ex. No. 118!) S=Solub1e. N S=Not soluble. SS=Somewhat soluble.

[Resin made in pilot plant size batch, approximately pcunds, corresponding to 69a of Patent 2,499,370 but this batch designated 11911.]

- Mix Which is Mix Which Re Starting Mix g of Removed for mains as Next ac Sample Starter Max. Max. Time Pressure Tempsrahrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs Lbs. Lbs. Lbs Lbs. Lbs. Lbs Sol- Res- Sol- Res- Sol- Res- Sol- Resvent in vent in vent in vent in First Stage Resin to EtO Molal Ratio 121.. 13.65 16. 0 13. 65 16. 35 3. 0" 9. 11. 45 2. 1 4. 1 4. 9 0. 9 150 1% NS Ex. No. 1191).

Second Stage Resin to EtO Molal Ratio 1:5. 10 12 0 10 12 10. 4. 52 5. 42 4. 81 5. 48 6. 58 5. 94 140 160 1242 S Ex. No. 12017.....

Third Stage Resin to EtO Molal Ratio 1:10- 5. 48 6. 58 5. 94 5. 48 6. 58 10. )4 S Ex. No. 1210.

Fourth Stage 'Resin toEtO....

Mola1 Ratio 1:15. 4.] 4. 9 0. 9 4.1 4. 9 l3. l5 180 171 1% 2 VS Ex. N o. 1220 Fifth Stage j Resin to 12170.... Molal Ratio 1:20. 3. 10 3. 72 0. 6S 3. 10 3. 72 13. 4? 320 VS Ex.No.l23b-...

S=So1ub1e. NS =Not soluble, VS=Very soluble.

Pheno'l for resin: Pam-secondary hutylphenel Date, July 14-15, 1948 Ald'ehyd-e' for resin? Formaldehyde [Resin made in'piloit'pisnt size batch,"approximately 25.p ounds, corresponding to 2a o'i Patent 2,499370 but this batehxdesignated 12/111. 1

. Mix Which is Mix Which'Re- Starting Mix g g figg Removedinr mains as'NPxt Sample Starter Max. Max. Tim, Pressu e; .Tempgra- Solubility Ibls. libs. 'gbls. abs. ms lbls. .gbs. Lbs lsibls. .gbs. UN Q oes-'- 0- es-' oes- 0- esvent in vent in vent in Eto went in Eto First Stage Resin to E130... V M01211 Ratio 1:1 14.45 15.55 0 14.45 .15. 4.25 5.97 Iii-38 1.75 8.48 9.17 2.50 .60 I50 71": NS Ex. N0. 124b Second Stage Resin to EtO Molal'Ratio 1:5" .8548 9.17 2.50 8. 48 9.17.1100 5.83 6. 32 11.05 2:65 2'85 4. 95 95 188 .93 SS Ex.No.125b

Third Stage Resinto EtO Molal Ratio 1:10. 4.82 5.18 o 4.82 5.18.1445 400 .183 .8 Ex. No. 126b Fourth Stage Resin to EtO Molal Ratio .1: 1'5 3.85 4.15 '0 3.85 4.15 17.10 120 .180 VS Ex. N0. 12% I Fifth Stage Resin to EtO Moial Ratio 1:20- 2.05 2.85 4. 95 2. 2.85 .15. v80 170 3h VB Ex. N0. 128!) S Soluble. NS =Not soluble. SS Somewhat sdiuble. VS Very soluble.

Phenol for Date August 12-13, 1948 xresen: Menthyl Aldehyde jfnnresin: Propiunuldeh'yde '[Resin'made 0n'pi1v5t 'plant's'ize 1ba.tch,rapproxlma.te1yf25 pounds corresponding 120 8111 .df Patent 2,499,370 but this batchflesignatedlZBmj 'Lfix Which is 1 Which Re- Starting Mix fig fi g' Removed [or mains 'as'iNext Sample Starter Max. I Pressu e; Tempgm- 3132 Solubility l bls. gbs. Lbs I bIs. .gbs. Lbs r b s. I bs. Lbs 1 .11 5. gas. Lbs ture, ..oesn.0- es- .oes- :0- esvent in Eto vent in vent in Eto went in Eto First Stage Resin to Et0. v V I Molai Ratio 1 ;12.'8 17.2 12.8 17.2 2.75 4.25 55.7 0.95 8.55 11.50 21. .150 .k N01: soluble. Ex. No. 129b- Second Stage Resin to EtO Molal Ratio 1:5 28:55 11. 5O 1. 80 8. 55 11.150 9.3 1 "4. 78 0. 42 "5. 2' B. 7.7 T5 08 34. 10 100 Ms Somewhat Ex. N0. 1300 soluble.

Third Stage Resin to EtO.. I Molal Ratio 1:10. 3. 77 5.08 4.10 3. 77 5.08 13.1 .100 .182 $2 Soluble. Ex. No. 1311) Fourth Stage Resinto EtO M0181 Ratio 1':l5 5.2 7.0 '1. 5.2V 1.0 .17.?0 3.10 .4..17 10.13 2.10 2.33 5.87 200 182 A Very soluble. Ex. No. 132b Fifth Stage lx i i i'i c fz'' 2.10 2 s3 6 s7 10 83 o a 9. i0 T 2. .2. .942 1 ;90 J50 Ex No. 1330 1s Verysolubie Phenol for resin: Para-tertiary amylphenol Date, August 27-31, 1948 [Resin made on pilot plant size batch, approximately 25 pounds, corresponding to 42a of Patent 2,499,370 but this batch designated as 134a.]

Aldehyde for resin: Furfural Mix Which is Mix Which Re- Starting Mix ii g figg of Removed for mains as Next Sample Starter Max. Max. Time 1 rljressure 'fempgllhrs Solubility Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. Lbs. am

Lbs. Lbs. Lbs. Lbs. Sol- Res- Sol- Res- 501- Res- 501- Resvent in Eto vent in Eto vent in Eto vent in Eto First Stage Resin to Et Molal Ratio 1:1 11. 2 l8. 0 11. 2 18. 0 3. 5 2. 4. 4 0. 8. 45 13. 6 2. 65 120 135 14; Not soluble. Ex. No. 1340 Second Stage 2. 65 8.45 13. 6 12.65 5.03 8.12 7. 55 3.42 5.48 5. 10 150 Somewhat soluble.

Third Stage Resin to EtO. M0121 Ratio 1:10 4. 5 8. 0 4. 5 8. 0 14. 5 2. 45 4. 35 7. 99 2. 05 3. 65 6. 60 180 163 $4 Soluble. Ex. No. 136b Fourth Stage Resin to EtO Molal Ratio 1:15-. 3. 42 5. 48 5.10 3. 42 5. 48 15.10 180 188 A; Very soluble. Ex. N0. 1371) Fifth Stage Resin to EtO Molal Ratio 1:20 2.05 3.65 6.60 2.05 3.65 13.35 1 1 H; Very soluble. Ex. No. 138!) i Phenol for resin: Menthyl Aldehyde for resin: Furfural Date, Sept. 23-24, 1948 [Resin made on pilot size batch, approximately 25 pounds, corresponding to 89a of Patent 2,499,370 but this batch designated as 189a.]

- Mix Which is Mix Which Re- Starting Mix gg figg or Removed for mains as Next Sample arter Max. Max. Tim nI)1- u re Eempslg hrs Solubility s.sq.1n. ure, .31 .22: gg 531 e22: ggsli: 522 6 21 522.- g vent in vent in vent in vent in First Stage Resin to EtO olal Ratio 10.25 17.75 10.25 17.75 2.5 2.65 4.60 0.65 7.6 13.15 1.85 90 150 l Not soluble. Ex. No. 139

Second Stage Resin to E110 Molal Ratio 7.6 13.15 1.85 7.6 13.15 9.35 5.2 9.00 6.40 2.4 4.15 2.95 80 177 $6 Somewhat Ex. No. 140 soluble.

Third Stage }4.22 6.9 4.22 6.98 10.0 90 165 $4 Soluble.

}3.76 6.24 3.76 62413.25 100 171 $4 Verysoluble.

}2.4 4.15 2.95 2.4 4.15 11.70 90 M; Verysoluble. Ex.N0.143b

Date, October 7-8, 1948 Phenol for resin: fiarawctyl Aldehyde for mesimtFatrfural El Resinmade on pilot plant size bateh, approximately '25 pounds, corresponding to-42a .of Patent 2,499,370with 206 partsby weight ofeommercial para-oetylphenol replacing 164 parts by weight ofpara-tertiary amylphenol but this batch designated as 144a,]

. Mix Which is Mix Which Re- Starting Mix figg figg of Removed for mains as Next Sample Starter Max. Max. Time lgnessure, 1I'emp51g hrs Solubility s. sq. 111. are, 52?: 122: gig 5: 1122: ggg- E31 i122: ggg 52?: 322: g ggvent in vent in vent in vent in First Stage Resin to Et0 Molal Ratio 1:1 12. 1 18. 6 12.1 18.6 3.0 5. 38 8.28 1.34 6. 72 10.32 1. 66 80 150 $42 Insoluble. EX. No. 144b.-

Second Stage Slight :tend- Resinto EtO. one .to- Molal Ratio 1:5 9.25 14. 9. 25 14. 25 11.0 3. 73 5. 73 4.44 5. 52 8.52 6.56 100 177 252 word he- Ex. No. 145b coming sol- .uble.

Third Stage Resin to E110" 1 Molal Ratio 1 6.72 10.32 1.66 6.72 10.32 14.91 4.97 7.62 11.01 1.75 2. 3.90 85 182 VA vFairly solu- Ex. No. 1465"-.- ble.

Fourth, Stage Resin toEtO Molal Ratio 1 5. 52 8. 52 6.56 5.52 8.52 19.81 100 176 X; Readily .501- Ex. No. 147b uble.

Fifth Stage Resin to EtO Molal Ratio 1 1. 2. 70 3.90 1. 75 2.70 8.4 160 M Quite .SOlli- Ex. No. 148b ble.

Phenol for resin: Para-phenyl Date, October 11-13, 1948 Aldehyde for resin: Furfural [Resin madeon pilot plant size batch, approximately 25 pounds. corresponding to 42a of Patent 2,499,370 with 170 parts by weight of commercial paraphenylphenol replaeing164 parts by we ght of para-tertiary amylphenol but this batch designated as 149a.]

Mix Which is Mix Which Re- Starting Mix fig figg of Removed for ,mains as Next Sample Starter Max. Max. Time Pressure, Temp era hrs Solubility lbls. gbs. Lbs r b s. Ibs. Lbs I b s. r bs. Lbs l b s. fins. Lbs 0- es-, 0-. es-. voes- 0- es- 4 vent in Eto vent in Eto vent in Eto vent in Dto First Stage Resin to EtO- Molal Ratio 1.11.. 13. 9 16. 7 13.9 16. 7 3.0 3. 50 4. 25 0.80 10.35 12.45 2.20 k; Insoluble. Ex. No. 149b Second Stage Resin to EtO 11511112 vteltld- Molal Ratio 1:5" 10. 35 12. 45 2. 20 10. 35 12. 45 12. 20 5. l5 6. 19 6. 06 5. 20 6. 26 6. 14 80 183 }'f; 0- Ex. No. 1501...... t?

bihty. Third Stage Resin to EtO Molal Ratio 1:10. 8. 90 10.7 8.90 10.70 19.0 5.30 6.38 11.32 3. 60 4. 32 7.68 90 193 A2 Fairly Solu- Ex. No. 051b ble.

Fourth Stage Resin to Et0. Molal Ratio l:15 5. 20 6. 26 6.14 5.20 6.26 16. 64 100 171 M; Readily sol- Ex. No. 1521)... -ub1e.

Fifth Stage Resin to EtO. MOIalBatio 1:20-. 3.60 4.32 .7168. 3. 60 4.32 15.68 Sample somewhat rubbery andge- 230 2 Ex. No. 1535-.- latinous but fairly soluble 

1. A PROCESS FOR BREAKING PETROLEUM EMULSIONS OF THE WATER-IN-OIL TYPE CHARACTERIZED BY SUBJECTING THE EMULSION TO THE ACTION OF A DEMULSIFLER INCLUDING A HYDROPHILE ESTER IN WHICH THE ACYL RADICAL IS THAT OF AN ALPHA-HALOGEN MONOCARBOXYLIC ACID HAVING NOT OVER 6 CARBON ATOMS AND THE ALCOHOLIC RADICAL IS THAT OF CERTAIN HYDROPHILE POLYHYDRIC SYNTHETIC PRODUCTS; SAID HYDROPHILE SYNTHETIC PRODUCTS BEING OXYALKYLATION PRODUCTS OF (A) AN ALPHA-BETA ALKYLENE OXIDE HAVING NOT MORE THAN 4 CARBON ATOMS AND SELECTED FROM THE CLASS CONSISTING OF ETHYLENE OXIDE, PROPYLENE OXIDE, BUTYLENE OXIDE, GLYCIDE, AND METHYLGLYCIDE, AND (B) AN OXYALKYLATION SUSCEPTIBLE, FUSIBLE, ORGANIC SOLVENT-SOLUBLE, WATER-INSOLUBLE PHENOL-ALDEHYDE RESIN; SAID RESIN BEING DERIVED BY REACTION BETWEEN A DIFUNCTIONAL MONOHYDRIC PHENOL AND AN ALDEHYDE HAVING NOT OVER 8 CARBON ATOMS AND REACTIVE TOWARD SAID PHENOL; SAID RESIN BEING FORMED IN THE SUBSTANTIAL ABSENCE OF TRIFUNCTIONAL PHENOLS; SAID PHENOL BEING OF THE FORMULA 